Liquid crystal display device and manufacturing method thereof

ABSTRACT

A liquid crystal display device, includes a first substrate including a first insulating substrate, a first thin film positioned on the first insulating substrate, and a first alignment layer positioned on the first thin film and including a first exposing area that exposes the first thin film, a second substrate facing the first substrate and including a second insulating substrate, a spacer positioned between the first substrate and the second substrate and including at least a part that corresponds to the first exposing area, and a liquid crystal layer positioned between the first substrate and the second substrate.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of Korean PatentApplication No. 10-2007-0080663, filed on Aug. 10, 2007, which is herebyincorporated herein by reference for all purposes as if fully set forthherein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a liquid crystal display device and amanufacturing method thereof, and more particularly, to a flexibleliquid crystal display device and a manufacturing method thereof.

2. Discussion of the Background

A liquid crystal display device includes a first substrate, a secondsubstrate facing the first substrate, and a liquid crystal layerinterposed between the first substrate and the second substrate.

Optical properties of the liquid crystal display device may be closelycorrelated with a cell gap, which is distance between the firstsubstrate and the second substrate. For example, the contrast ratio andthe viewing angle are known to be dependent on multiplication of doublerefraction An of the liquid crystal molecules and the cell gap.Accordingly, if the cell gap is not uniform, the optical propertiesthereof may become non-uniform. If the liquid crystal display device isbent, especially in a flexible liquid crystal display device, it may bedifficult to maintain a uniform cell gap.

If transformation happens in the flexible liquid crystal display device,the cell gap corresponding to an area where the transformation happensbecomes narrower than the cell gap in other areas.

Accordingly, the transmittance of the liquid crystal layer correspondingto the transformed portion may deteriorate, which may deteriorate thebrightness uniformity of the liquid crystal display device.

SUMMARY OF THE INVENTION

The present invention provides a liquid crystal display device and amanufacturing method thereof stably maintaining a cell gap.

Additional features of the present invention will be set forth in thedescription which follows and, in part will be obvious from thedescription, or may be learned by practice of the present invention.

The present invention discloses a liquid crystal display deviceincluding a first substrate, a second substrate, a spacer, and a liquidcrystal layer. The first substrate includes a first insulatingsubstrate, a first thin film positioned on the first insulatingsubstrate, and a first alignment layer positioned on the first thin filmand including a first exposing area that exposes the first thin film.The second substrate faces the first substrate and includes a secondinsulating substrate. The spacer is positioned between the firstsubstrate and the second substrate and includes at least a part thatcorresponds to the first exposing area. The liquid crystal layer ispositioned between the first substrate and the second substrate.

The present invention also discloses a manufacturing method of a liquidcrystal display device, including providing a first substrate andproviding a second substrate. The first substrate includes a firstinsulating substrate, a first thin film positioned on the firstinsulating substrate, and a first alignment layer positioned on thefirst thin film to include a first exposing area that exposes the firstthin film. The second substrate includes a second insulating substrateand a second alignment layer disposed on the second insulatingsubstrate. The method further includes positioning a liquid crystalpolymer composition, which includes a polymer having greater chemicalaffinity for the first thin film than for the first alignment layer anda liquid crystal molecule having greater chemical affinity for the firstalignment layer than for the first thin film on one of the firstsubstrate and the second substrate, on one of the first substrate andthe second substrate the liquid crystal polymer composition, disposingone of the first substrate and the second substrate on the other of thefirst substrate and the second substrate, and curing the liquid crystalpolymer composition to form a spacer after the polymer of the liquidcrystal polymer composition becomes concentrated in an areacorresponding to the first exposing area.

The present invention discloses a manufacturing method of a liquidcrystal display device, including providing a first substrate andproviding a second substrate. The first substrate includes a firstinsulating substrate, a thin film positioned on the first insulatingsubstrate, and a first alignment layer positioned on the thin film andincluding a first exposing area that exposes the thin film. The secondsubstrate includes a second insulating substrate. The method furtherincludes disposing the second substrate on the first substrate so thatthe first substrate and the second substrate face each other with aspace therebetween, disposing a liquid crystal polymer composition inthe space, the liquid crystal polymer composition including a polymerhaving greater chemical affinity for the thin film than to the firstalignment layer and a liquid crystal molecule having greater chemicalaffinity for the first alignment layer than for the thin film, andcuring the liquid crystal polymer composition to form a spacer after thepolymer of the liquid crystal polymer composition becomes concentratedin an area corresponding to the first exposing area.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherexplanation of the invention and are incorporated in and constitute apart of this specification, illustrate embodiments of the invention, andtogether with the description serve to explain the principles of theinvention.

FIG. 1 is an exploded perspective view of a liquid crystal displaydevice according to a first exemplary embodiment of the presentinvention.

FIG. 2 is a sectional view taken along line II-II of FIG. 1.

FIG. 3 is a flowchart showing a method of manufacturing the liquidcrystal display device according to the first exemplary embodiment ofthe present invention.

FIG. 4, FIG. 5, FIG. 6, FIG. 7, FIG. 8, and FIG. 9 describe the methodof manufacturing the liquid crystal display device according to thefirst exemplary embodiment of the present.

FIG. 10 is a sectional view showing transformation of the liquid crystaldisplay device according to the first exemplary embodiment of thepresent invention.

FIG. 11 is a sectional view of a liquid crystal display device accordingto a second exemplary embodiment of the present invention.

FIG. 12 is a flowchart showing a manufacturing method of the liquidcrystal display device according to the second exemplary embodiment ofthe present invention.

FIG. 13, FIG. 14, FIG. 15, and FIG. 16 describe the method ofmanufacturing the liquid crystal display device according to the secondexemplary embodiment of the present.

FIG. 17 is a sectional view of a liquid crystal display device accordingto a third exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

The invention is described more fully hereinafter with reference to theaccompanying drawings, in which embodiments of the invention are shown.This invention may, however, be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein.Rather, these embodiments are provided so that this disclosure isthorough, and will fully convey the scope of the invention to thoseskilled in the art. In the drawings, the size and relative sizes oflayers and regions may be exaggerated for clarity. Like referencenumerals in the drawings denote like elements.

It will be understood that when an element or layer is referred to asbeing “on” or “connected to” another element or layer, it can bedirectly on or directly connected to the other element or layer, orintervening elements or layers may be present. In contrast, when anelement is referred to as being “directly on” or “directly connected to”another element or layer, there are no intervening elements or layerspresent.

Hereinafter, a liquid crystal display device 1 according to a firstexemplary embodiment of the present invention will be described byreferring to FIG. 1 and FIG. 2.

As shown in FIG. 1, the liquid crystal display device 1 according to thefirst exemplary embodiment of the present invention includes a firstsubstrate 100, a second substrate 200, a spacer 300, a liquid crystallayer 400, and a sealant 500.

The first substrate 100 is bigger than the second substrate 200, thearea inside the sealant 500 is a display area, and the area outside ofthe sealant 500 is a non-display area. The first substrate 100 includesa gate line 121 extending to the display area, a gate pad 122 connectedto the gate line 121 and positioned to the non display area, a data line131 extending to the display area, and a data pad 132 connected to thedata line 131 and positioned in the non display area.

The gate line 121 and the data line 131 are connected to a thin filmtransistor 140, which is shown in FIG. 2. The gate line 121 applies agate signal (a gate on voltage and a gate off voltage) to the thin filmtransistor 140, and the data line 131 applies a data voltage to the thinfilm transistor 140.

The gate pad 122 and the data pad 132 are respectively applied with thegate signal and the data voltage from an external unit.

Alternatively, the gate pad 122 may be omitted.

The second substrate 200 is positioned on the first substrate 100 toface the first substrate 100.

The spacer 300 and the liquid crystal layer 400 are positioned in thedisplay area. The spacer 300 uniformly maintains a cell gap, that is, aninterval between the first substrate 100 and the second substrate 200,together with the sealant 500. The spacer 300 will be described indetail by referring to FIG. 2.

The sealant 500 attaches the first substrate 100 and the secondsubstrate 200, and surrounds the liquid crystal layer 400 together withthe first substrate 100 and the second substrate 200. The sealant 500 isdisposed in the non-display area around the display area and may includea photoresist material.

The liquid crystal display device 1 according to the first exemplaryembodiment of the present invention will be described in more detail byreferring to FIG. 2.

At first, related to the first substrate 100, the thin film transistor140 is disposed on a first insulating substrate 110. The thin filmtransistor 140 is connected to the gate line 121 and the data line 131.

An insulating layer 150 is disposed on the thin film transistor 140. Acontact hole 51 is formed in the insulating layer 150 to expose the thinfilm transistor 140.

A pixel electrode 160 is positioned on the insulating layer 150.

The pixel electrode 160 may include a transparent conductive materialsuch as indium tin oxide (ITO), indium zinc oxide (IZO), or the like,and is connected to the thin film transistor 140 through the contacthole 151.

A first thin film 170 is positioned on the pixel electrode 160.

The first thin film 170 may be positioned over the entire display areaof the liquid crystal display device 1 and has greater chemical affinityfor a polymer 352 than for liquid crystal molecules 351 contained in aliquid crystal polymer composition 350 shown in FIG. 8. For example, ifthe polymer 352 is NOA65®, an ultraviolet ray curable adhesive made byNorland in America, and the liquid crystal molecule 351 is MLC6610®, aliquid crystal mixture made by Merck in Germany, the first thin film 170may be AL1H659®, a polyimide material made by JSR in Japan.

A first alignment layer 180 including a first exposing area 181 exposingthe first thin film 170 is positioned on the first thin film 170.

The first alignment layer 180 is arranged in a matrix by thelattice-shaped openings of the first exposing area 181, and determinesan alignment direction of the liquid crystal molecules 351 of the liquidcrystal layer 400. The first alignment layer 180 may include polyimide,silicon oxide, or the like, and has greater chemical affinity for theliquid crystal molecules 351 than for the polymer 352 contained in theliquid crystal polymer composition 350. For example, if the polymer 352is NOA65®, and the liquid crystal molecules 351 are MLC6610®, the firstalignment layer 180 may be JALS684®, a vertical alignment layer made byJSR in Japan.

The second substrate 200 may include a black matrix 220 disposed on thesecond insulating substrate 210.

The black matrix 220 may have a lattice shape and prevents an externallight from being supplied to a channel area of the thin film transistor140. The black matrix 220 may include chromium oxide or an organicmaterial including a black pigment.

A color filter 230 is disposed between the black matrixes 220. The colorfilter 230 includes three sub layers 230 a, 230 b, and 230 csequentially and repeatedly arranged and having different colors.

An over coat layer 240 is disposed on the color filter 230 and the blackmatrixes 220. The over coat layer 240 supplies a planar surface andprotects the color filter 230.

A common electrode 250 is disposed on the over coat layer 240. Thecommon electrode 250 may include a transparent conductive material suchas ITO, IZO, or the like, and applies a voltage to the liquid crystallayer 400 together with the pixel electrode 160 to adjust an arrangementstate of the liquid crystal layer 400.

A second alignment layer 260 is disposed on the common electrode 250.

The second alignment layer 260 determines the alignment direction of theliquid crystal molecules 351 contained in the liquid crystal layer 400together with the first alignment layer 180. The second alignment layer260 may be patterned to enable the liquid crystal molecules 351 to behorizontally aligned or vertically aligned together with the firstalignment layer 180. The second alignment layer 260 may be positionedover the entire second insulating substrate 210.

The second alignment layer 260 may include polyimide, silicon oxide, orthe like, and has greater chemical affinity for the liquid crystalmolecules 351 than for the polymer 352 contained in the liquid crystalpolymer composition 350. For example, if the polymer 352 is NOA65®, andthe liquid crystal molecules 351 are MLC6610®, the second alignmentlayer 260 may be JALS684®.

The spacer 300 is positioned to correspond to the first thin film 170exposed by the first exposing area 181 of the first alignment layer 180.The spacer 300 directly contacts the surfaces of the first substrate 100and the second substrate 200. The spacer 300 has a lattice shapecorresponding to the first exposing area 181, and the liquid crystallayer 400 is divided by the spacer 300.

The spacer 300 maintains the cell gap due to the contact of the latticeshape with the surfaces of the first substrate 100 and the secondsubstrate 200.

The spacer 300 may include an ultraviolet ray curable resin such as anacrylic resin and may further include an epoxy resin, which may includethermal curable resin, a hardener of an amine series, and a filler suchas alumina powder. The spacer 300 has greater chemical affinity for thefirst thin film 170 than for the first alignment layer 180. For example,if the first alignment layer 180 is JALS684®, and the first thin film170 is AL1H659®, the spacer 300 may be NOA65®.

The liquid crystal layer 400 is positioned in a space defined by thespacer 300, the first substrate 100, and the second substrate 200.

The liquid crystal layer 400 includes the liquid crystal molecules 351,and it directly contacts the first alignment layer 180 and the secondalignment layer 260, which determine the alignment direction of theliquid crystal molecules 351.

The liquid crystal molecules 351 of the liquid crystal layer 400 may benematic, smectic, or cholesteric liquid crystals, and have greaterchemical affinity for at least one of the first alignment layer 180 andthe second alignment layer 260 than for the first thin film 170. Forexample, if the first alignment layer 180 and the second alignment layer260 are JALS684®, and the first thin film 170 is AL1H659®, the liquidcrystal molecules 351 may be MLC6610®.

Hereinafter, a method of manufacturing the liquid crystal display device1 according to the first exemplary embodiment of the present inventionwill be described referring to FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6,FIG. 7, FIG. 8, and FIG. 9.

As shown in FIG. 3, the manufacturing method of the liquid crystaldisplay device 1 according to the first exemplary embodiment of thepresent invention includes providing the first substrate 100 (S100),providing the second substrate 200 (S200), positioning the liquidcrystal polymer composition 350 on the first substrate 100 (S300),disposing the second substrate 200 on the first substrate 100 (S400),and curing the liquid crystal polymer composition to form the spacer 300(S500). Initially, as shown in FIG. 4, the first substrate 100 isprovided (S100).

After the gate line 121, the data line 131, the gate pad 122, the datapad 132, the thin film transistor 140, the insulating layer 150, and thepixel electrode 160 are disposed on the first insulating substrate 100,the first thin film 170 is disposed in the display area.

The first thin film 170 may be formed through an ink jetting method, aflexo printing method, or the like.

The first alignment layer 180 is disposed on the first thin film 170.The first alignment layer 180 is arranged in a matrix by thelattice-shaped openings of the first exposing area 181 to expose thefirst thin film 170.

The first alignment layer 180 may be formed through a micro contactprinting method using a mold or through the same method as the firstthin film 170. Then, an alignment pattern such as a vertical alignment,a horizontal alignment, or the like may be formed in the first alignmentlayer 180 through a rubbing method or the like.

Then, as shown in FIG. 5, the second substrate 200 is formed (S200).

After the black matrix 220, the color filter 230, the over coat layer240, and the common electrode 250 are disposed on the second insulatingsubstrate 210, the second alignment layer 260 is disposed in the displayarea.

The second alignment layer 260 may be disposed over the entire displayarea and may be formed through the ink jetting method, the flexoprinting method, or the like. Then, an alignment pattern such as avertical alignment pattern, a horizontal alignment pattern, or the likemay be formed in the second alignment layer 260 through the rubbingmethod or the like.

The order in which the first substrate 100 and the second substrate 200are formed may vary. For example, the second substrate 200 may be formedbefore forming the first substrate 100, or the first substrate 100 andthe second substrate 200 may be concurrently formed.

Then, the liquid crystal polymer composition 350 is positioned on thefirst substrate 100 (S300).

As shown in FIG. 6, the sealant 500 having a close loop shape isarranged around the display area on the first substrate 100.

The sealant 500 includes a light curable material, a thermal curablematerial, or the like, and may be formed through a screen mask method, adispense method, or the like.

Then, the liquid crystal polymer composition 350 is positioned on thedisplay area of the first substrate 100, which the sealant 500surrounds, through a dropping method.

The liquid crystal polymer composition 350 includes the polymer 352,shown in FIG. 8, having greater chemical affinity for the first thinfilm 170 than for the first alignment layer 180, and the liquid crystalmolecules 351, shown in FIG. 8, having greater chemical affinity for thefirst alignment layer 180 and the second alignment layer 260 than forthe first thin film 170. The polymer 352 may include an ultraviolet raycurable resin.

Alternatively, the sealant 500 may be arranged around the display areaof the second substrate 200, and the liquid crystal polymer composition350 may be positioned on the second substrate 200.

Then, the second substrate 200 is disposed on the first substrate 100(S400). Alternatively, the first substrate 100 may be disposed thesecond substrate 200.

As shown in FIG. 7, the second substrate 200 is disposed on the firstsubstrate 100 so that the first alignment layer 180 and the secondalignment layer 260 face each other with the liquid crystal polymercomposition 350 interposed therebetween.

Then, the liquid crystal polymer composition 350 is cured to form thespacer 300 (S500). This operation will be described by referring to FIG.8 and FIG. 9.

As shown in FIG. 8, the polymer 352 and the liquid crystal molecules 351contained in the liquid crystal polymer composition 350 interposedbetween the first substrate 100 and the second substrate 200respectively move toward the first exposing area 181 and the firstalignment layer 180 due to different chemical affinities.

Since the polymer 352 has greater chemical affinity for the first thinfilm 170 than for the first alignment layer 180 and the second alignmentlayer 260, the polymer 352 moves toward the portion of the first thinfilm 170 that is exposed by the first exposing area 181.

Since the liquid crystal molecules 351 have greater chemical affinityfor the first alignment layer 180 and the second alignment layer 260than for the first thin film 170, the liquid crystal molecules 351 movesto toward the first alignment layer 180 and the second alignment layer260.

As shown in FIG. 9, after the polymer 352 becomes more concentrated inan area corresponding to the first exposing area 181 than in an areacorresponding to the first alignment layer 180, an ultraviolet ray isirradiated toward the liquid crystal polymer composition 350 from anexternal part of at least one of the first substrate 100 and the secondsubstrate 200.

The polymer 352 in the area corresponding to the first exposing area 181is cured by the ultraviolet ray irradiated to the liquid crystal polymercomposition 350, and the polymer 352 remaining in the area correspondingto the first alignment layer 180 moves toward the polymer 352 in thearea corresponding to the first exposing area 181 due to the chemicalaffinity between the vicinal polymers 352 to be cured.

As described above, the polymer 352 is concentrated in the areacorresponding to the first exposing area 181 to be cured to form thespacer 300. The spacer 300 contacts the surfaces of the first substrate100 and the second substrate 200. Accordingly, the first substrate 100and the second substrate 200 may be fixedly attached by the spacer 300.

Hereinafter, a case in which the liquid crystal display device 1 iselastically transformed will be described by referring to FIG. 2 andFIG. 10.

The first insulating substrate 110 and the second insulating substrate210 may include glass, quartz, or plastic. For example, for the plastic,polycarbonate, polyimide, polyethersulfone (PES), polyarylate (PAR),polyethylenenaphthalte (PEN), or polyethyleneterephthalate (PET) may beemployed.

If the first insulating substrate 110 and the second insulatingsubstrate 210 include plastic, the liquid crystal display device 1 maybe flexible. Accordingly, it may be difficult to maintain a uniform cellgap. Also, if the liquid crystal display device 1 is elasticallytransformed, the cell gap in an area corresponding to the location ofthe elastic transformation becomes narrower than the cell gap in otherareas of the display.

Accordingly, the transmittance of the liquid crystal layer 400 in anarea corresponding to the elastically transformed portion maydeteriorate, which may partially deteriorate the brightness of theliquid crystal display device 1.

However, as shown in FIG. 2, since the spacer 300 fixedly contacts thesurfaces of the first substrate 100 and the second substrate 200, evenif the first insulating substrate 110 and the second insulatingsubstrate 210 include flexible plastic, the cell gap d between the firstsubstrate 100 and the second substrate 200 may be stably maintained bythe spacer 300, thereby minimizing the non-uniformity of the spacebetween the first substrate 100 and the second substrate 200.

Also, as shown in FIG. 10, if the liquid crystal display device 1 istransformed, the cell gap d corresponding to the transformed portion maybe maintained by the spacer 300. Accordingly, although thetransformation may occur, the brightness may be uniformly maintainedover the entire liquid crystal display device 1.

Although the liquid crystal layer 400 corresponding to each pixelelectrode 160 is divided by the spacer 300 having the lattice shape, aportion of the liquid crystal layer 400 is compactly positioned in eachspace defined by the first substrate 100, the second substrate 200, andthe spacer 300.

Hereinafter, a liquid crystal display device and a manufacturing methodthereof according to a second exemplary embodiment of the presentinvention, and a liquid crystal display device according to a thirdexemplary embodiment of the present invention will be described.

Hereinafter, a distinct part from the first exemplary embodiment may bedescribed, and the configuration of the first exemplary embodiment and aknown configuration may be applied to a part about which the descriptionis omitted.

Initially, a liquid crystal display device 2 according to the secondexemplary embodiment of the present invention will be described byreferring to FIG. 11.

The second substrate 200 includes a black matrix 220, a color filter230, an over coat layer 240, and a common electrode 250 disposed on asecond insulating substrate 210.

A second thin film 270 is disposed on the common electrode 250.

The second thin film 270 is positioned over the entire display area ofthe liquid crystal display device 2 and has greater chemical affinityfor a polymer 352 than for liquid crystal molecules 351 contained in aliquid crystal polymer composition 350, as shown in FIG. 14.

A third alignment layer 280 having a second exposing area 281 exposingthe second thin film 270 is positioned on the second thin film 270. Thesecond exposing area 281 is positioned to correspond to a first exposingarea 181.

The third alignment layer 280 is disposed in a matrix by thelattice-shaped openings of the second exposing area 281, and itdetermines an alignment direction of the liquid crystal molecules 351 ofa liquid crystal layer 400. The third alignment layer 280 may includepolyimide, silicon oxide, or the like, and has greater chemical affinityfor the liquid crystal molecules 351 than for the polymer 352 containedin the liquid crystal polymer composition 350.

The third alignment layer 280 determines the alignment direction of theliquid crystal molecules 351 contained in the liquid crystal layer 400together with the first alignment layer 180. The third alignment layer280 may be patterned to enable the liquid crystal molecules 351 to behorizontally aligned or vertically aligned with the first alignmentlayer 180.

A spacer 300 is positioned in an area corresponding to the second thinfilm 270 exposed by the second exposing area 281 of the third alignmentlayer 280, and the first thin film 170 exposed by the first exposingarea 181 of the first alignment layer 180. The spacer 300 directlycontacts with surfaces of the first substrate 100 and the secondsubstrate 200. The spacer 300 has a lattice shape corresponding to thefirst exposing area 181 and the second exposing area 281, and the liquidcrystal layer 400 is divided by the spacer 300. At least a part of thespacer 300 is positioned to correspond to the first thin film 170 andthe second thin film 270.

The spacer 300 maintains a cell gap due to the contact of the latticeshape with surfaces of the first substrate 100 and the second substrate200.

Hereinafter, the manufacturing method of the liquid crystal displaydevice 2 according to the second exemplary embodiment of the presentinvention will be described by referring to FIG. 11, FIG. 12, FIG. 13,FIG. 14, FIG. 15, and FIG. 16.

As shown in FIG. 12, the manufacturing method of the liquid crystaldisplay device 2 according to the second exemplary embodiment of thepresent invention includes providing the first substrate 100 (S 110),providing the second substrate 200 (S210), disposing the secondsubstrate 200 on the first substrate 100 (S310), positioning the liquidcrystal polymer composition 350 between the first substrate 100 and thesecond substrate 200 (S410), and curing the liquid crystal polymercomposition to form the spacer 300 (S510).

Initially, the first substrate 100 and the second substrate 200 areprovided (S110 and S210).

As shown in FIG. 13, the first substrate 100 may be formed by the samemethod as in the first exemplary embodiment. After the black matrix 220,the color filter 230, the over coat layer 240, and the common electrode250 are disposed on a second insulating substrate 210 of the secondsubstrate 200, the second thin film 270 is disposed in the display area.

The second thin film 270 may be formed through an ink jetting method, aflexo printing method, or the like.

The third alignment layer 280 is disposed on the second thin film 270.The third alignment layer 280 is arranged in a matrix by thelattice-shaped openings of the second exposing area 281 to expose thesecond thin film 270.

The third alignment layer 280 may be formed through a micro contactprinting method using a mold, or may be formed through the same methodas the second thin film 270. Then, an alignment pattern such as avertical alignment pattern, a horizontal alignment pattern, or the likemay be formed in the third alignment layer 280 through a rubbing methodor the like.

The order in which the first substrate 100 and the second substrate 200are formed may vary. For example, the second substrate 200 may be formedbefore forming the first substrate 100, or the first substrate 100 andthe second substrate 200 may be concurrently formed.

Then, the second substrate 200 is disposed on the first substrate 100(S310).

As shown in FIG. 13, a sealant 500 having an open loop shape to surroundthe display area is disposed on the first substrate 100. Alternatively,the sealant 500 may be disposed on the second substrate 200.

Then, the second substrate 200 is disposed on the first substrate 100 sothat the first alignment layer 180 and the third alignment layer 280face each other and are spaced apart to define a space therebetween.

Then, the liquid crystal polymer composition 350 is positioned betweenthe first substrate 100 and the second substrate 200 (S410).

As shown in FIG. 14, the liquid crystal polymer composition 350 may beinjected into the space between the first substrate 100 and the secondsubstrate 200 through an opened space in the sealant 500 using a vacuumfilling apparatus 10. Here, the polymer 352 contained in the liquidcrystal polymer composition 350 may include an ultraviolet ray curableresin or a thermal curable resin.

When the pressure of the space defined by the first substrate 100, thesecond substrate 200, and the sealant 500 decreases, the first substrate100 and the second substrate 200 contact the liquid crystal polymercomposition 350 contained in a liquid crystal accommodating unit 11, andthe liquid crystal polymer composition 350 is injected into the spacedefined by the first substrate 100 and the second substrate 200 throughthe opening in the sealant 500 due to a capillary phenomenon and apressure difference. After the liquid crystal polymer composition 350 isinjected, the first substrate 100 and the second substrate 200 arespaced apart from the liquid crystal accommodating unit 11.

Then, the spacer 300 is formed (S510).

As shown in FIG. 15, the polymer 352 contained in the liquid crystalpolymer composition 350 interposed between the first substrate 100 andthe second substrate 200 moves toward the first exposing area 181 andthe second exposing area 281 due to chemical affinity, and the liquidcrystal molecules 351 move toward the first alignment layer 180 and thethird alignment layer 280 due to chemical affinity.

Since the polymer 352 has greater chemical affinity for the first thinfilm 170 and the second thin film 270 than for the first alignment layer180 and the third alignment layer 280, the polymer 352 moves toward thearea where the first thin film 170 and the second thin film 270 arerespectively exposed by the first exposing area 181 and the secondexposing area 281.

Since the liquid crystal molecules 351 have greater chemical affinityfor the first alignment layer 180 than for the first thin film 170, andhave greater chemical affinity for the third alignment layer 280 thanfor the second thin film 270, the liquid crystal molecules 351 movetoward the first alignment layer 180 and the third alignment layer 280.

As shown in FIG. 16, after the polymer 352 becomes more concentrated inan area corresponding to the first exposing area 181 and the secondexposing area 281 than in an area corresponding to the first alignmentlayer 180 and the third alignment layer 280, an ultraviolet ray or heatis supplied to the liquid crystal polymer composition 350 from anexternal part of at least one of the first substrate 100 and the secondsubstrate 200.

The polymer 352 in the area corresponding to the first exposing area 181and the second exposing area 281 is cured by the ultraviolet ray or heatsupplied to the liquid crystal polymer composition 350, and theremaining polymer 352 in the area corresponding to the first alignmentlayer 180 and the third alignment layer 280 moves toward the polymer 352in the area corresponding to the first exposing area 181 and the secondexposing area 281 due to the chemical affinity between the vicinalpolymers 352 to be cured.

As described above, the polymer 352 becomes concentrated at the firstexposing area 181 and the second exposing area 281 to be cured to formthe spacer 300. Here, the spacer 300 contacts surfaces of the firstsubstrate 100 and the second substrate 200.

As described above, in the liquid crystal display device and themanufacturing method thereof according to the second exemplaryembodiment, the second substrate 200 includes the third alignment layer280 including the second exposing area 281 corresponding to the firstexposing area 181 so that the polymer 352 contained in the liquidcrystal polymer composition 350 may move toward the first exposing area181 and the second exposing area 281 more rapidly than the in firstexemplary embodiment, which may reduce the manufacturing time of theliquid crystal display device 2.

Also, since the second substrate 200 has greater chemical affinity forthe polymer 352 of the liquid crystal polymer composition 350 to formthe spacer 300, the spacer 300 may further fixedly contact the secondsubstrate 200 in addition to the first substrate 100 so that the cellgap of the liquid crystal display device may be fixedly maintained.

Hereinafter, a liquid crystal display device 3 according to the thirdexemplary embodiment of the present invention will be described byreferring to FIG. 17.

The second substrate 200 includes a black matrix 220, a color filter230, an over coat layer 240, and a common electrode 250 disposed on asecond insulating substrate 210.

A first alignment layer 180 of a first substrate 100 determines analignment direction of a liquid crystal layer 400.

The first alignment layer 180 may determine a horizontal alignment or avertical alignment of the liquid crystal layer 400.

As described above, since the configuration of the liquid crystaldisplay device 3 according to the third exemplary embodiment is simpleas compared to the first exemplary embodiment and the second exemplaryembodiment, the manufacturing cost of the liquid crystal display device3 may be reduced, and a manufacturing time of the liquid crystal displaydevice 3 may be reduced.

In the above exemplary embodiments, the spacer 300 may have a continuouslattice shape. Alternatively, the spacer 300 may have a dot shape, ahoneycomb shape, or other shapes.

As described above, the exemplary embodiments of the present inventionprovide a liquid crystal display device that may stably maintain a cellgap and a manufacturing method thereof.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the spirit or scope of the invention. Thus, it isintended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

1. A liquid crystal display device, comprising: a first substratecomprising a first insulating substrate, a first thin film positioned onthe first insulating substrate, and a first alignment layer positionedon the first thin film, the first alignment layer comprising a firstexposing area that exposes the first thin film; a second substratefacing the first substrate and comprising a second insulating substrate;a spacer positioned between the first substrate and the secondsubstrate, the spacer comprising at least a part that corresponds to thefirst exposing area; and a liquid crystal layer positioned between thefirst substrate and the second substrate.
 2. The liquid crystal displaydevice of claim 1, wherein the second substrate further comprises asecond alignment layer positioned on the second insulating substrate. 3.The liquid crystal display device of claim 2, wherein the liquid crystallayer directly contacts the first alignment layer and the secondalignment layer.
 4. The liquid crystal display device of claim 2,wherein the second substrate further comprises a second thin filmpositioned between the second alignment layer and the second insulatingsubstrate, and the second alignment layer comprises a second exposingarea that exposes the second thin film.
 5. The liquid crystal displaydevice of claim 4, wherein at least a part of the spacer is positionedto correspond to the second exposing area.
 6. The liquid crystal displaydevice of claim 4, wherein the second exposing area is positioned tocorrespond to the first exposing area.
 7. The liquid crystal displaydevice of claim 2, wherein the spacer directly contacts the firstsubstrate and the second substrate.
 8. The liquid crystal display deviceof claim 7, wherein the first exposing area has a lattice shape.
 9. Theliquid crystal display device of claim 2, wherein at least one of thefirst insulating substrate and the second insulating substrate comprisesa plastic insulating substrate.
 10. The liquid crystal display device ofclaim 2, wherein the spacer comprises at least one of an ultraviolet raycurable resin and a thermal curable resin.
 11. A manufacturing method ofa liquid crystal display device, comprising: providing a first substratecomprising a first insulating substrate, a first thin film positioned onthe first insulating substrate, and a first alignment layer positionedon the first thin film, the first alignment layer comprising a firstexposing area that exposes the first thin film; providing a secondsubstrate comprising a second insulating substrate and a secondalignment layer that is disposed on the second insulating substrate;positioning a liquid crystal polymer composition on one of the firstsubstrate and the second substrate, the liquid crystal polymercomposition comprising a polymer having greater chemical affinity forthe first thin film than for the first alignment layer, and a liquidcrystal molecule having greater chemical affinity for the firstalignment layer than for the first thin film; disposing one of the firstsubstrate and the second substrate on the other of the first substrateand the second substrate; and curing the liquid crystal polymercomposition to form a spacer after a the polymer of the liquid crystalpolymer composition becomes concentrated in an area corresponding to thefirst exposing area.
 12. The method of claim 11, wherein the providingthe second substrate comprises forming a second thin film having greaterchemical affinity for the polymer than does the second alignment layer,the second thin film being positioned between the second insulatingsubstrate and the second alignment layer, and the second alignment layercomprises a second exposing area through which the second thin film isexposed.
 13. The method of claim 12, wherein the second exposing areacorresponds to the first exposing area when one of the first substrateand the second substrate is disposed on the other of the first substrateand the second substrate.
 14. The method of claim 11, wherein the spacerdirectly contacts the first substrate and the second substrate.
 15. Themethod of claim 14, wherein the first exposing area has a lattice shape.16. The method of claim 11, wherein the liquid crystal polymercomposition is cured using at least one of an ultraviolet ray and heat.17. A manufacturing method of a liquid crystal display device,comprising: providing a first substrate comprising a first insulatingsubstrate, a thin film positioned on the first insulating substrate, anda first alignment layer positioned on the thin film, the first alignmentlayer comprising a first exposing area that exposes the thin film;providing a second substrate comprising a second insulating substrate;disposing the second substrate on the first substrate so that the firstsubstrate and the second substrate face each other with a spacetherebetween; disposing a liquid crystal polymer composition in thespace, the liquid crystal polymer composition comprising a polymerhaving greater chemical affinity for the thin film than for the firstalignment layer, and a liquid crystal molecule having greater chemicalaffinity for the first alignment layer than for the thin film to thedistanced space; and curing the liquid crystal polymer composition toform a spacer after the polymer of the liquid crystal polymercomposition becomes concentrated in an area corresponding to the firstexposing area.
 18. The method of claim 17, wherein the providing thesecond substrate further comprises forming a second alignment layer onthe second insulating substrate.
 19. The method of claim 18, whereinproviding the second substrate comprises forming a second thin filmhaving greater chemical affinity for the polymer than does the secondalignment layer, the second film being positioned between the secondinsulating substrate and the second alignment layer, and the secondalignment layer comprises a second exposing area through which thesecond thin film is exposed.